ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A01SF6XC08
    *a Width
    *b Height
    *c Protrusion Height

    Note

    It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.


    1. Using a plastic hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 8 mm (0.315 in.) 11 mm (0.433 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    A01SFT7N03
    *1 8.5 mm (0.335 in.)
    *2 8.0 mm (0.315 in.)
    *3 18 mm (0.709 in.)

    Note

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. Using an E6 "TORX" socket wrench, install the stiffening crankcase stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01SFJKN09
      *1 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *2 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent
      Standard Seal Diameter
      Area Specified Condition
      Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      A 4.5 to 5.5 mm (0.177 to 0.217 in.)
      Application Length A
      56 mm (2.20 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the crankcase within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

    2. A01SFIMN10

      Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 138 mm (5.43 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 70 mm (2.76 in.)

    3. Recheck the torque for the bolts (1) and (2).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Wipe off any excess seal packing with a clean piece of cloth.

  4. INSTALL OIL PUMP ASSEMBLY

    Click here

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  6. INSTALL OIL PAN DRAIN PLUG


    1. A01SFHF

      Install a new gasket and the oil pan drain plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  7. INSTALL REAR ENGINE OIL SEAL

    Click here

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. A01SFOQN06

      Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug (A), and install the No. 1 taper screw plug (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine at least 1 hour after installing the No. 1 taper screw plug.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug (B), and install the No. 1 taper screw plug (B).

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the No. 1 taper screw plug.

  9. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. A01SFENC07
      *a Adhesive

      Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the ventilation valve sub-assembly within 3 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the ventilation valve sub-assembly.

    2. A01SFVK

      Install the ventilation valve sub-assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  12. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem ends.

    2. Install the 16 valve stem caps to the cylinder head.

      Note

      Do not drop the valve stem caps into the cylinder head.

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it.

      Click here

    2. Install the 16 valve lash adjuster assemblies to the cylinder head.

      Note

      Install the valve lash adjuster assembly to the same place it was removed from.

  14. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01SFK7C04
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

    2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A01SFFAC01
    *a Width
    *b Height
    *c Protrusion Height

    Note

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.


    1. Using a plastic hammer, tap in a new camshaft housing straight pin to the specified protrusion height.

      Standard Straight Pin
      Item Protrusion Height Height Width
      Straight pin 6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)

  16. INSTALL NO. 1 CAMSHAFT BEARING

    Click here

  17. INSTALL OIL CONTROL VALVE FILTER


    1. A01SFKG

      Check that no foreign matter is on the mesh of the oil control valve filter.

    2. Install the oil control valve filter.

      Note

      Do not touch the mesh when installing the oil control valve filter.

  18. INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  19. INSTALL NO. 2 CAMSHAFT

    Click here

  20. INSTALL CAMSHAFT

    Click here

  21. INSTALL CAMSHAFT BEARING CAP

    Click here

  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  23. INSTALL CAMSHAFT TIMING SPROCKET

    Click here

  24. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01SFB1

      Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

      Tech Tips

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

  26. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01SFH2

      Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  27. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  28. INSTALL CRANKSHAFT TIMING SPROCKET

    Click here

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  31. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  32. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  33. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  34. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here[ Click here

  35. INSTALL WATER INLET SUB-ASSEMBLY STUD BOLT

    Tech Tips


    • There are 2 installation types for the water inlet sub-assembly.

      Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.

      This procedure is for type A.

    • If a stud bolt is deformed or its threads are damaged, replace it.


    1. A01SFS1N03
      *1 21 mm (0.827 in.)
      *2 9 mm (0.354 in.)
      *3 34 mm (1.34 in.)

      Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  36. INSTALL WATER INLET SUB-ASSEMBLY

    Tech Tips

    There are 2 installation types for the water inlet sub-assembly.

    Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.


    1. Type A:


      1. A01SFL1

        Install a new gasket and the water inlet sub-assembly with the bolt and 2 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Type B:


      1. A01SFSV

        Install a new gasket and the water inlet sub-assembly with the 3 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  38. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  39. INSTALL CRANKSHAFT PULLEY

    Click here

  40. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  41. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A01SFFPC03
      *a Part to Cut Off

      Using a cutter knife, cut off the seal part of the removed gasket.

    2. A01SFHHC03
      *1 Spark Plug Tube Gasket without Seal Part
      *2 New Spark Plug Tube Gasket

      Using a hammer and the spark plug tube gasket which has had the seal part cut off, uniformly tap in a new spark plug tube gasket all the way.

      Note


      • Keep the lip free of foreign matter.

      • Do not tap the new spark plug tube gasket.

      Tech Tips

      If a spark plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.

  43. INSTALL CYLINDER HEAD COVER GASKET


    1. A01SFM0C03
      *1 Cylinder Head Cover Sub-Assembly
      *2 Cylinder Head Cover Gasket

      Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note


      • Remove any oil from the contact surfaces.

      • Misalignment between the center of the cylinder head cover sub-assembly rib and the center of the cylinder head gasket tab should be 4.0 mm (0.157 in.) or less.

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01SFGT

      Install 2 new gaskets to the camshaft bearing cap.

    2. A01SFMJ

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Diameter
      4.0 mm (0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    3. A01SFDM

      Install the cylinder head cover sub-assembly with a new seal washer and the 13 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Misalignment between the contact surfaces of the timing chain cover sub-assembly and the camshaft housing sub-assembly and the center of the cylinder head cover gasket tab should be 4.0 mm (0.157 in.) or less.

      A01SFNUC03
      *1 Timing Chain Cover Sub-Assembly
      *2 Camshaft Housing Sub-Assembly
      *3 Cylinder Head Cover Gasket

  45. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01SFUGC11
      *a Adhesive

      Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the oil pressure switch within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour after installation.

    2. A01SF9C

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  46. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A01SFNH

      Install a new gasket and the engine coolant temperature sensor.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  47. INSTALL KNOCK CONTROL SENSOR


    1. A01SFTEN07

      Install the knock control sensor with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      Make sure that the knock control sensor is in the correct position.

  48. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01SFQN

      Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

    2. A01SFA3

      Install the crankshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01SFKN

      Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve assembly.

    2. A01SFIX

      Install the camshaft timing oil control valve with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve (timing surface with cylinder head cover).

      • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control valve.

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. A01SFEE

      Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

    2. A01SFD1

      Install the camshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure that the O-ring is not cracked or pinched when installing the camshaft position sensor.

  51. INSTALL SPARK PLUG

    Click here

  52. INSTALL ENGINE COVER JOINT BOLT


    1. A01SF9W

      Install the 3 engine cover joint bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  53. INSTALL WIRING HARNESS CLAMP BRACKET


    1. A01SF7Y

      Install the wiring harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  54. INSTALL OIL FILLER CAP GASKET


    1. A01SFM9

      Install the gasket to the oil filler cap sub-assembly.

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A01SFPA

      Install the oil filler cap sub-assembly.